Support made from stone and tension-resistant material

ABSTRACT

The invention describes a girder profile made of stone material and tensile-resistant material, which is preferably made of 002 in order to fix greenhouse gases. This is intended to replace steel girders and aluminum girders with sustainable building materials.The invention adopts the principle of dovetailing from timber construction and transfers this principle to the structure made of stone material and fiber material, in that the planes of the profile, which usually meet orthogonally, overlap geometrically with regard to the tension-stable material parts or at least meet in one cutting plane.Such materials made of mineral substances and fibrous materials are significantly lighter, more durable and more ecological than such carriers made of metallic materials.

The present invention relates to the development of a standard profile commonly used in the construction sector, which today is usually made of steel material, known as a T-beam or double T-beam.

Such a girder consists of three elongated plates, which are connected to each other in the longitudinal direction and arranged at right angles to one another, has a pressure-stable upper chord and a tension-stable lower chord, also called a flange, and a web connecting the lower chord and upper chord, which is typically arranged symmetrical in the middle of the flanges. There are also U-profiles with a ridge on one of the two sides, or box profiles with 2 ridges on the sides.

The invention also relates to such or similar and other profiles such as:

-   -   P-profile with parallel inner surfaces of the flanges, also         known as “Peiner” or Peiner carrier     -   U-profile with inclined inner surfaces of the flanges     -   U-profile with parallel inner surfaces of the flanges     -   T-profile isosceles     -   L-profile (also angle iron, angle profile or angle bracket)     -   as well as all possible variations of box sections and     -   V-profiles and combinations of these profiles

With such profiles, an optimal load-bearing capacity for the respective application is achieved in relation to the mass of the material used and thus its weight.

In the case of I-beams, the height of the central bar or web essentially determines the rigidity of the beam. Secondary measures for increasing the rigidity are the targeted increase in the tensile stability of the lower flange and the targeted increase in the compressive rigidity of the upper flange, Since such girders are hot-rolled from steel, the upper and lower chords are identical for the sake of simplicity.

The advantage of steel beams of this type is cheap manufacturability in large quantities and reliable load-bearing capacity. Defects are rare in such profiles and can be neglected in practical use. In addition, additional steel parts for connecting beams to other load-bearing parts can be easily welded at the construction site at any time and place as required.

The disadvantage is the extremely high density of steel at 7.8 g/cm³ and the fact that steel production involves large amounts of energy and high CO₂ emissions. So far, the only replacement for steel has been aluminum, which is lighter but has an even higher ecological footprint than steel. For this reason, the quantities of mass steel required cannot be produced with aluminum.

For this reason, steel is generally regarded as an indispensable building material, which apparently cannot be replaced even from a climate protection point of view, which is why work is being done on reducing steel with hydrogen, which makes steel even more energy-intensive to produce.

However, in recent reports by SITRA, commissioned by the Finnish government, it is clear that today's levels of steel, aluminum and cement alone account for the remaining amounts of CO₂ to be emitted by 2100, if that 2° C. target according to the Paris climate Agreement is to be met. This fact makes it compelling to first reconsider the indispensability paradigm of steel or metal.

EP 106 20 92 and EP 273 94 71 describe how steel and aluminum can be replaced by a combination of stone and carbon fiber laminate (CFRP—carbon fiber composite) if the stone is given the lack of tensile stability by the extremely stiff carbon fiber. The connection between stone and fiber is made with the help of resins, for example epoxy resins or high-temperature stable binders based on water glass and silicone, which are able to crosslink or bond with the carbon material. Under certain circumstances, these connections also produce a prestress which can be permanently built into or through the connection.

The invention describes a technical way of how such a double T-beam can be exemplary designed to transfer the utilization of the CFRP stone composite (CFS—CarbonFaserStein or CarbonFiberStone) to practicable and optimized structures or geometries, as being known in the construction area already. The technical design is shown in FIGS. 1 to 8 as an example for a double T-beam and a single T-beam. The main challenge here is to connect the surfaces that are perpendicular to one another in a force-fitting manner without local stress peaks causing the geometry to fail completely at an early stage through local failure. The frictional connection of the surfaces is in principle established with the help of glues or adhesives. This applies to the production of the CFRP stone composite (CFS) and to the connection of the CFS parts themselves. For this purpose, the base plate material in FIG. 1 is first produced, which arranges the carbon layer (4) in the middle between two stone plates.

Then the parts to be connected are provided with dovetailing, just as in carpentry wooden panels are prepared with dovetails, which optimize the orthogonal connection of wooden panels. In the case of wood, too, the effect is ultimately used that orthogonally meeting fiber layers are connected to one another in a cross-over or overlapping manner, since butt bonding without geometric overlapping would only be limited to the adhesion of the adhesive, which would ultimately fail quickly due to its insufficient tensile stability. Due to the dovetailing of the transitions, the power transmission from one tension-stable plane to the other orthogonal tension-stable plane is almost completely achieved when the two tension-stable planes, in our exemplary case in FIGS. 1 to 8 the carbon layers—within the stone layer(s)—, are spatially overlapping in view of the cross sections.

In fracture tests, it could be proven that a double T-beam made of CFS plates can carry similarly high loads as a comparable steel beam, whereby the CFS beam is significantly lighter, since stone with a specific weight of 2.8 g/cm3 is significantly lighter than steel, and stone and carbon cause significantly less CO₂ emissions during production than steel. Savings of 30-50% can be expected. The overall construction shows itself to be elastic in the fracture test, without the bonded dovetail breaking up when the beam bends.

In order to ensure sufficient tensile stability in the lower belt, only relatively thin and light layers of carbon are required, which also reduce the total weight in relation to the total volume. The compressive rigidity on the upper chord and in the web is achieved by the stone component. In addition to carbon, many other fiber materials can also be used that have a significantly smaller ecological footprint than carbon fibers. Glass fibres, basalt fibres, stone fibres, steel fibers and flax fibers are also suitable as examples depending on the application. From a technical point of view, however, the carbon fiber is of particular importance because, in contrast to most other fibers, it has a significantly higher tensile stiffness. This applies in particular to graphene-based structures, which are not fibers in the strict sense, but can also be used as reinforcement in the future. Another effective measure to further reduce the carbon footprint is the production of carbon and graphene from sustainable resources, for example from algae oil or other vegetable-based oils from algae or yeasts, carbon fibers from lignin, i.e. from wood waste from paper production, or carbon fibers from synthetically produced methanol using the extended Fischer-Tropsch synthesis and water-gas shift reaction. Graphene can also be obtained directly from CO₂ using electrical energy. In these cases, a part of the building material—in the case that the tension-resistant layer consists of carbon fibers or graphene—essentially comes from CO₂ sources, whereby the carbon, which previously had a climate-damaging effect in the form of CO₂, is now bound permanently within the fiber and thus also in the Building material in solid form. This is one of the reasons why carbon fiber is particularly important as a material with high tensile strength.

One of the many possible versions of the invention describes in FIG. 1 and FIG. 2 a CFS plate (1) as the upper chord and a second underlying stabilizing CFS plate (2) as the lower chord, each with an internal carbon layer (4) in the plates, with a web (3) arranged vertically to the plates (1) and (2) which is made of CFS, having also an internal carbon layer, which stiffens the overall arrangement. FIG. 1) shows the dovetailing and cutouts (5) of all panels which allow the panels to have interlocking structures which ensure cross-panel adhesion when the panels are interlocked with adhesives. The optimization of the components is achieved by the upper chord getting more stone contingent than the lower chord and the lower chord more carbon contingent than the upper chord. In the same way the carbon footprint can be optimized.

FIGS. 3 and 4 show the structure of FIG. 2 in cross section (F-F) and (G-G), with which the two plates (1) and (2) are mechanically force fitting connected with the help of dovetails via the CFS plate (3).

The same is shown for a T-beam in FIGS. 5 to 8 as an example. The two designs are representative of the principle of connecting the CFS panels with the help of dovetailing of the edges to be glued together in order to also connect all possible other structures at right angles or at an angle and force-fitting by the fact that the carbon surfaces with high tensile strength viewed from the perspective of the cross section are in intersect or at least meet at a cutting line. 

1. Arrangement of a girder profile with two or more slabs made of natural stone, artificial stone such as concrete or resin- or mineral-bound stone powder, glass or ceramic—hereinafter referred to as stone slab or stone slabs —, the stone slabs being mechanically tension-stabalized with the aid of at least one tensile-resistant layer or incorporated tension-resistant materials, such as incorporated fibers, characterized in that the (stone) slabs, arranged at a certain angle to one another, are equipped with the help of dovetailing and/or cutouts, at which the tension-resistant layers or the tension resistant materials are meeting each other at least approximately or overlapping in their planes being arranged on top of each other, while this geometry of the in such a way arranged tesile—resistant stone slabs is fixed by bonding—or in case of artificial stone are cast-curing in the liquid phase—in such a way, that the respective fiber orientations meet each other or overlap.
 2. Arrangement according to claim 1, characterized in that the respective tension-stable layer lies within the stone layers.
 3. Arrangement according to claim 1, characterized in that the respective stone layer lies within the tension-stable layers.
 4. Arrangement according to claim 1, characterized in that the layering of the respective plate is different and has even more alternating layers of stone layers and tensile layers.
 5. Arrangement according to claim 1, characterized in that the fibers are incorporated into the concrete or stone mass in the case of concrete and resin—or mineral-bound stone powder.
 6. Arrangement according to claim 1, wherein the tension-stable layer consists of fiber materials, wood fibers, steel fibers or graphene.
 7. Arrangement according to claim 6, characterized in that the fibers are glass, stone, carbon, aramid, bamboo, wood or flax fibers or a mixture of these fibers.
 8. Arrangement according to claim 1, characterized in that the respective binding matrix of the carrier has an epoxy resin, polyester resin, phenolic ester resin, polyimide resin, cyanate ester resin, vinyl ester resin, melamine resin, polyurethane resin or silicone resin base or a mixture of these resins, which preferably have shrinking properties.
 9. Arrangement according to claim 7, characterized in that the carbon fibers come from fossil sources or come from regenerative sources.
 10. Arrangement according to claim 1, characterized in that the raw materials for the carbon fibers, the resins and adhesives consist of vegetable oils, algae oils, yeast oils, lignin or other vegetable raw materials such as flax fibers.
 11. Arrangement according to claim 1, characterized in that the raw materials for the carbon fibers, the resins and adhesives come from plant residues that remain in papermaking, for example in the form of lignin and other plant residues, which are delivering fermented yeast oils, with help of yeast, for the biogenic production of PAN-based carbon fibers, graphene, resins and binders.
 12. Arrangement according to claim 1, characterized in that PAN-based carbon fibers and/or resins and binders are produced from CO2 using synthetic processes.
 13. Arrangement according to claim 1, characterized in that the carbon fibers, resins and adhesives are produced from CO2 using the water-gas shift reaction and the Fischer-Tropsch synthesis.
 14. Arrangement according to claim 1, characterized in that in the case of resin- or mineral-bound stone powder, the binder consists of a mixture of resin and mineral adhesives which have the highest possible temperature stability.
 15. Arrangement according to claim 1, characterized in that the mineral binder consists of a base of waterglass.
 16. Arrangement according to claim 1, characterized in that the tension-resistant material or at least a part thereof is prestressed in relation to the pressure-resistant material. 